Starter problem
 

Hi My XT600 3AJ Will not usually start by using the electric start.
I have put a new Yuasa battery on 2 days ago Battery was filled and charged for 5 hours before fitting the bike did start first time but a few hours later would not start. I put jump leads from my truck to the bike battery and still wont start just turns over and over, but if I push start it will start stright away it feels like the back wheel only has to turn half a turn and engine will fire.
I have taken the starter motor apart and looked ok and fairly clean inside.
Any ideas whats up?

Hi Bolla, is the starter motor spinning ok. Try checking the gears behind the small cover above left engine cover. The gears might be loose on their pins, circlips loose. Or it might be the starter clutch not picking up. If its the starter clutch, you will need to pull off the CDI magnito and check the rollers in the clutch. Might just need a clean, had a KLR do the same, just pulled it apart cleaned with WD40 and it worked ok after that. Xt 600 seems similar .How was Eastern Europe trip ? Brian.

Earth connections
 

Friend of mine had the same problem. Was solved by cleaning and tightening all earth connections in the ignition system. I don´t have a real explanation, but it might be that the vibrations made by the starter motor somehow rattle the earth connections so no sparks are produced. Consider to make some additional earth connection on your electrical system, as the single one from the battery into the wiring loom is a bit flimsy.

Auke

sounds like starter clutch
 

Sounds like the clutch cam arrangement behind the magnito.
As Brian has said check other things eg. the gear train that drives the starter clutch cam first..
Not such a biggy.
Of course these clutch cams do chew out if they aren't lubed correctly.. Always change that engine oil and filter regularly.

another word
 

If it is the starter clutch cam and if it is just dirty you could remove the left crankcase cover and try the dodgy method of blasting it with compressed air to.
I don't think this will truely clean it but it may remove enough buildup to get it working.
The reason I mention this is removing the magneto can be a reasonable task if you don't have a rattle gun and and at least the correct puller. I had a terible time getting min off.

Thanks for the replys
My problem now is that I managegd to break my engine case while fitting a kick start.

I have a 99 xtz660 and have gone through several starter motor clutches. Never had that problem on any other bike that I have owned. The symptoms are that the starter motor just whirs but the motor doesn't spin over. I think it is a weakness in the xtz.

Check your start engine solenoid..mine stopped working... the start engine was trying to start the engine that's you it didn't stop turning due to the jumper cables...[ the big metal shiny thing that is behind the frame on the left side of the battery casing....:cool4:

staerter clutch, weakness of xtz, you got it!
 

I think the same , Martian 74. The starter clutch in xtz is really a prob. ı have a '96 xtz , everything going perfect, till one day,I touch the starter and the starter clutch gets crazy! The mechanic here (which is enough old to see many xtx between 94 an 99 told me that it is a common defect with xtz660 94-99. and I believe so!! (now waiting for the part to change the starter clutch ) :)

oh b*gg*r!!

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